1398

2631744/2024/O/o PED/INFRA-1/RDSO
Technical Specification for on track Multipurpose Tamper for B.G.
(1676 mm Gauge)
(Specification No: TM/HM/MPT-367 Rev.03 of 2021 04 of 2024)

1.0 GENERAL:

1.1 With the mechanization of track maintenance activities on Indian Railways, machines are
required for spot tamping of concrete sleepers on plain track and turnouts and special
locations like switch expansion joints, glued joints, L-Xing with check rails, ballasted track
with guard rails on bridges, curve etc. without removing check/guard rails. These machines
have to be very sturdy and suitable for heavy duty operation to tamp the modern concrete
sleeper‟s turnouts and plain track with concrete sleepers. Simultaneously the machine has
to be suitable for the transport of engineering materials, equipment and workmen for day to
day working. This specification has been designed for such a multi-purpose machine
hereinafter called “machine‟‟.

1.2 This technical specification has been drafted to reflect the performance and quality
requirements of the machine in a neutral manner without bias to any specific manufacturer.
Bidders are requested to carefully study the specification and assure that their machine fully
comply therewith. If a bidder feels that his machine can substantially meet the performance
and quality requirements of the machine but does not fully satisfy a particular system
specification, he shall mention the same in the statement of deviation from the specification,
giving the details how the functional requirements are going to be met with.

1.3 The bidder shall specify the make/model offered and furnish a detailed technical description
of the same. System/subsystem of the working mechanism of the machine as per clause
3.0 in particular and all the items of the specification in general shall be described in detail
in the “Technical Description” along with sketches to show the manner in which the
requirements of the specification are accomplished by the machine (model) offered.

1.4 Photographs of the type of machine/other similar type of on-track machines manufactured
offered in working mode and technical literature shall be enclosed with the offer. The
photographs shall also show close-ups of various working assemblies/systems and the full
machine/other similar type of on-track machines. The tenderer shall also furnish a video in
compact disc (computer enabled) or DVD or USB showing the working of machine/other
similar type of on-track machines under field conditions. Tenderer shall also submit the
names of countries & railways where the offered machine/other similar type of on-track
machines are working and where their working at site can be visited by Indian Railway
officials.

1.5 The bidder shall be entirely responsible for the execution of the contract strictly in
accordance with the terms and conditions of the specification not withstanding any
approval, which RDSO or the inspecting officer may have given:

 Of the detailed drawings prepared by the bidder.

 Of his sub- bidders for materials, components & sub-assemblies.
 Of other parts of the work involved in the contract.
 Of the tests carried out by the bidder/sub- bidder or RDSO or the inspecting officer.

2.0 DIMENSIONAL AND OPERATING REQUIREMENT:

2.1 The diesel-powered self-propelled machine shall be of latest design, robust, reliable and
suitable for working on the Indian Railways plain track, transition and curved track (up to

Page 1 of 39
 1399
2631744/2024/O/o PED/INFRA-1/RDSO
10°) and turnouts and special locations as mentioned at clause 1.1 above on Broad Gauge
(1676 mm). It shall be basic tamping machine for tamping of plain track as well as points
and crossing. The machine shall be provided with end- cabins at either end and be capable
of being driven from these cabins at full speed in travel mode. Additional working cabin may
be provided to facilitate the view of working area during working. The design and
dimensions of the machine and components shall be to metric standards and shall comply
with provision of Indian Railways Schedule of Dimensions-1676 mm gauge (BG), revised,
2004 incorporating all correction slips/amendments. Quality assurance during
manufacturing of the machine shall be as per ISO-9001. The welding standard followed for
manufacturing of machine shall be to ISO:3834 or EN:15085 or any other equivalent
standard for welding railway vehicle and components. The manufacturer shall specify the
standard followed and certify that it meets the welding standard mentioned above.

2.2 The machine shall be self-propelled bogie type vehicle with minimum 2 bogies (4-axles).

2.3 The design and dimensions of the machine and components shall be to metric standards
and shall comply with provision of Indian Railways Schedule of Dimensions-1676 mm
gauge (BG), revised, 2022 incorporating all correction slips/amendments. The profile of the
machine (including its units) longitudinally and in cross section during transfer as self-
propelled machine or towed in train formation as last vehicle shall be within the Indian
Railways Schedule of Dimensions–1676 mm gauge (BG), revised, 2004 incorporating all
correction slips/amendments. The maximum moving dimensions (MMD) is enclosed in
Annexure-I. Whenever required, The tenderer shall provide sketches of the machine in plan
and elevation and shall give calculation along with Vogel's diagram for maximum moving
dimensions on 10° curve to show the extent of lateral shift at the ends, centre and any other
relevant cross sections. It shall be to ensure that the machine does not cause infringement
while moving on a 10° curve at any cross section.

2.4 In the past Indian Railways to the Indian Railways Schedule of Dimensions-1676 mm
gauge (BG), revised, 2004 incorporating all correction slips/amendments of such
dimensions as rigid wheel base, length of stocks, distance apart of bogie centres and
maximum height of floor above rail level in certain track machines after due consideration of
their design features vis-à-vis safety and operation requirements of Indian Railways.
However, condonation of an infringement in another track machine in the past does not by
itself entitle the manufacturer to assume acceptance of the same in other track machines by
Indian Railways. Where an infringement to Indian Railways Schedule of Dimensions–1676
mm gauge (BG), revised, 2004 incorporating all correction slips/amendments is considered
necessary by the manufacturer as intrinsic to the design of the machine for meeting the
work performance requirements laid down in this specification while meeting the safety and
operational requirements of Indian Railway, the condonation of the same may be permitted
by Indian Railways. However, only those infringements which are acceptable shall be
permitted. No condonation will be permitted to the dimensions mentioned in Indian
Railways Schedule of Dimensions-1676 mm gauge (BG), revised, 2022 incorporating all
correction slips/amendments.

2.5 Adequate clearance shall be allowed so that no component/part shall infringe the minimum
clearance of 91 mm from rail level while travelling up to condemnation limit of wheel.

2.6 Wherever applicable Axle load of the machine shall be less than 20.32 t 22.82 t with
minimum axle spacing of 1830 1800 mm. Load per metre shall not exceed 7.67 t. Axle
loads up to 22.82 t and lower axle spacing may be permitted, provided the load
combinations do not cause excessive stresses in the tracks & bridges of Indian Railways.
Stresses in the tracks & bridges shall be calculated by IR/RDSO based on design data
submitted by the firm as per (Annexure IV), and decision of IR/RDSO shall be final in this
regard.

Page 2 of 39
 1400
2631744/2024/O/o PED/INFRA-1/RDSO
2.7 The maximum and minimum permitted diameter of new wheel is 1092 mm and 740 mm
respectively. However it shall have a desirable wheel diameter of 914 mm. Minimum
permitted diameter of worn wheel is 710 mm. The machine shall have a desirable wheel
diameter of 914 mm (new wheel profile). However, lesser diameter up to 763 mm (new
wheel profile) can also be considered, provided it meets the condition laid down in Clause
2.4, 2.5 & 2.6 at its condemnation limit as per design and provided the rail wheel contact
stresses for 72 UTS rails are within permissible limits. The new wheel shall have a
minimum wear margin of 50 mm before reaching condemnation limit. Forged wheels to
Indian Railways profile shall be provided on the machine. It is desirable that 50 mm margin
between new and permitted worn wheel diameter shall be available, but this shall not be
less than 30 mm. The worn-out wheel diameter (condemning worn out diameter) based on
the criteria of rail wheel contact stresses for various maximum axle loads are as under:

Maximum Axle load (tonne) Minimum worn out wheel diameter (mm)
22.82 908.00
22.00 878.00
21.50 860.00
21.00 841.00
20.32 816.00
20.00 805.00
19.50 787.00
19.00 768.00
18.50 750.00
18.00 732.00
17.50 713.00

Permitted worn out wheel diameter shall be specified by the manufacturer. The diameter of
wheel for assessment of permitted axle load will be the worn-out wheel diameter. The new
wheel profile in the machine shall be as per Indian Railways standard drawing attached as
Annexure-VII which is titled as “WORN WHEEL PROFILE”.

Note: Annexure-VII “WORN WHEEL PROFILE” is currently standard new wheel profile of
Indian Railways.

2.8 Wheels shall be conforming to Indian Railways Standard R-19/93 with latest revision or
European Standard EN13262 with latest revision or any other equivalent standard (for
product requirement) and design shall duly conform to European Standard EN 13979 with
latest revision or other equivalent standard. The supplier shall mention the standard
followed & shall submit certificate for detailed design calculation along with material
parameters at the time of supply of the machine. However, in case of wheels sourced from
already supplying Indian suppliers, 3rd party/RITES Inspection certificate of the wheels to
be provided in lieu of design and material parameters certificate.

2.9 The non-powered axles shall be conforming to Indian Railways Standard R-16/95 with
latest revision or European Standard EN 13261(EA1N) with latest revision or any other
equivalent standard. The supplier shall submit certificate for detailed design calculation
along with material parameters at the time of supply of the machine. However, in case of
non-powered axles sourced from already supplying Indian suppliers, 3rd party/RITES
Inspection certificate of the non-powered axles to be provided in lieu of design and material
parameters certificate.

2.10 The powered axles shall be conforming to Indian Railways Standard R-43/92 with latest
revision or European Standard EN 13261 (EA4T) with latest revision or any other
equivalent standard (for product requirement). The design shall conform to 13104
Page 3 of 39
 1401
2631744/2024/O/o PED/INFRA-1/RDSO
13103:1:2017 or latest any other equivalent standard. The supplier shall mention the
standard followed & submit certificate for detailed design calculation along with material
parameters at the time of supply of the machine. However, in case of powered axles
sourced from already supplying Indian suppliers, 3rd party/RITES Inspection certificate of
the non-powered axles to be provided in lieu of design and material parameters certificate.

2.11 The machine shall be capable of negotiating curves up to 10° curvature (175 m radius),
super elevation up to 185 mm, maximum cant deficiency 75 mm and gradients up to 1 in 33
(3%) in travel mode. The supplier shall specify the minimum attainable speed under the
above limiting conditions. The machine shall be able to work on single/multiple lines as well
as between platforms without infringing the traffic movement on the adjoining track.

2.12 The machine shall be capable of continuous operation during the varying atmospheric and
climatic conditions occurring throughout the year in India. The range of climatic conditions is
as follows:

Ambient temperature : - 15°C to 55° C

Altitude : UP to 1750 2250 m above mean sea level
Relative Humidity : Up to 100%
Maximum rail temperature : 70° C 76° C

All the system components on the tamping machine shall be covered by roof or other
suitable sturdy covering so that the system & components vulnerable to moisture ingress
are not adversely affected during rains and the machine is able to work continuously even
during rains.

2.13 During transfer from one station to another, It shall be capable of travelling on its own at a
speed of 80 kmph 70 kmph and at a speed of 100 kmph 70 kmph when hauled in a train
formation as last vehicle. Since the machine is likely to cover long distances on its own
power, the travel drive system shall be robust to sustain these requirements during the life
of the machine. It shall be possible to drive the machine in both directions at the same
speed. Driving cabin shall be at both end of the machine for this purpose. The machine
shall be capable of hauling 8-wheeler coaches/wagons (90 ton 65 t approximately) at the
specified speeds above and as per conditions specified in clause 2.11. It shall be able to
negotiate sharpest gradient of up to 1 in 33 prevailing on Indian Railways.

2.14 The machine shall be capable of working without requiring power block in electrified
sections. 25 KV or 2X25 KV AC power supply is used for traction through an overhead wire
at 5500 4800 mm above rail level. On bridges and tunnels, the height is restricted to 4800
mm.

2.15 The machine or its any part shall not infringe the adjoining track as per “Indian Railways
Schedule of Dimensions–1676 mm gauge (BG), revised, 2004 2022 incorporating all
correction slips/amendments”, while working as well as opening and closing of work. While
working, also it shall not infringe the adjoining track and It shall be possible to permit trains
at full speed on that the adjoining track. Minimum spacing of tracks is 4265 mm centre to
centre.

2.16 The machine shall also be capable of carrying about 12 05 trackmen along with their tools.
Suitable seating arrangement and adequate space shall be provided.

2.17 There shall be one loading platform for keeping the tools and small P. way
materials/machines at one end of the machine of length not less than 7000 mm so as to
carry the half length of rails (6500 mm). The width of this open platform shall be equal to
the width of the machine as per the permitted schedule of dimension prevalent on Indian
Page 4 of 39
 1402
2631744/2024/O/o PED/INFRA-1/RDSO
Railways as mentioned above. The loading platform shall be provided all-around with a
sidewall/ Railing of minimum 450 to 600 mm height to protect the men and materials from
falling. The approximate gross tonnage expected on this loading platform shall be limited
up to 7.0 t and the detail of engineering tools & materials required on this loading platform
is as given in annexure-VI attached.

2.17 All operations for work and travel shall be controlled from a spacious fully enclosed cabin
permitting unobstructed view in both directions.

3.0 WORKING MECHANISM:

3.1 The machine shall be capable of tamping plain track as well as for spot attention of points
and crossings. and other miscellaneous track locations, handling of P. way material
including rails, sleepers, switches & Crossings, their stacking on the material platform. It
shall also be capable to tamp effectively the special track locations such as level crossing
with check rails, SEJ portion, ballasted track with guard rails on bridges, glued joint, curve
etc.

3.2 The machine shall be capable of automatic lifting, leveling, lining and tamping of track to
achieve the laid down track geometry standards, with proper packing for various kind of
track structures.

3.3 Separate split head tamping unit shall be provided for each rail and each unit comprising of
tamping tools shall be operated hydraulically. Each of the two halves of the tamping units
shall be able to be lowered and put into action separately from the other. Additionally, both
halves of the unit shall be able to be displaced laterally. It shall be possible to adjust the
tamping tools such that all accessible tamping zones on either side of the rails and sleepers
are tamped effectively. The tamping units shall be provided with necessary arrangements
for lateral shifting to adjust them on the rails in curves, turnout, SEJ and other such special
track locations. It shall be possible to tamp all four rails of the switch up to heel block. The
minimum lateral adjustment of tamping units (for both outer and inner) shall not be less than
270 mm from their normal position. It shall be possible to rotate and adjust tamping unit
from operator‟s seat for tamping of slanting sleepers in turnout. Since the machine is
predominantly to be used for spot attention and tamping on such spots may be required to
be done without any general lift, the tamping system shall be capable of giving effective
tamping at spots and correct the track geometry even when no general lift is given.

3.4 Tamping action shall be based on vibratory squeeze principle to achieve a durable
compaction with tamping tools operating under the same pressure but independent of one
another.

3.5 Amplitude of vibration, vibration pressure, vibration frequency, squeezing pressure,

squeezing time and tamping depth of tamping tools in tamping units shall be such that
durable compaction under the sleeper is achieved. Details of all the above parameters will
be submitted in the offer.

3.6 The squeezing action shall stop automatically after the tamping tools encounter the
resistance from the ballast equal to the pre-selected squeezing pressure. The squeezing
pressure and squeezing time shall be variable so that it can be adjusted according to
ballast conditions.

3.7 The lifting system shall be such that the track can be lifted without bearing on the ballast. It
shall be possible to lift track up-to 150 mm in one go depending on the requirement. While
working on track with no limitation of space, the lifting system shall hold the rail
continuously rather than releasing and re-lifting the rail at every tamping cycle. To ensure
easy lift at all locations the machine shall be provided with lifting hooks and lifting rollers
Page 5 of 39
 1403
2631744/2024/O/o PED/INFRA-1/RDSO
clamp both or any similar device capable of lifting the track as mentioned above. However,
the lifting/lining system and actual tamping shall be so synchronized that the track is stiffly
held in position and there is no movement in the track when the tamping tool is inserted for
tamping. This is required to ensure that the lift and slew are not altered during the process
while track is being tamped. It shall also be capable to lift properly the glued insulated joint,
switch expansion joint and special joints with one meter long fishplate.

3.8 The working cabin shall be so located that the operator faces towards the direction of
movement of machine to facilitate tamping of plain track. The lifting/lining units shall
normally be so located that they are visible to the operator from the working cabin and their
operation by operator shall not require assistance of another person. Camera with monitor
shall be provided for the assistance of operator if required. To monitor the working of
machines, closely from anywhere in the country from any location, suitable number of IP
based cameras are to be installed. The cameras shall be fixed on machine at such location
that the live video of the important working units of machine which are working on track,
location of worksite and post-work track can be seen by the authorized person with
commonly used browsers in India over the internet. Camera shall be password protected,
decentralized and IP based. It shall have function of recording built-in and thus can record
directly to any standard storage media, such as SD cards. Internal memory space of 500
GB shall also be available.

3.9 The free length between the two bogies shall be long enough to permit the track lifting and
lining up-to 150 mm in one go, having 60 kg rails on concrete sleeper, without excessive
stresses in the rail or on the lifting mechanism.

3.10 The machine shall be provided with automatic leveling equipment which will permit correct
leveling of the track and points & crossings including provision of super elevation along with
tamping.

3.11 The tamping tool holding arrangement in tamping arm of tamping bank shall be such that
no hammering is required for fixing and removing the tamping tools. Also tamping tools
shall not loosen/drop during working.

3.12 The machine shall be fitted with automatic lining equipment capable of carrying out lining
simultaneously with leveling. It shall be possible to adjust the lining unit longitudinally
depending upon the position of sleepers and fittings etc, in the turnout. If required, the
machine shall be able to slew the track up to 150 mm in one go. The lining unit shall have
two rollers for each rail or other suitable arrangement to avoid derailing of the lining rollers.

3.13 The machine shall be able to achieve the following tolerance: -

Unevenness : ± 1 mm on 3.6 m Chord

Cross level : ± 1 mm
Alignment : ± 2 mm on 7.2 m Chord
Twist : 1 mm/m on 3.0 m base

Also not more than 10 peaks per km should exceed the value specified as under:

Unevenness : 4 mm on 3.6 m Chord

Cross level : -
Alignment : ± 3 mm on 7.2 m Chord
Twist : 1.39 mm/m on 3.0 m base.

3.14 It shall be possible to control the target track geometry parameters, in infinitely variable
steps, from the operator‟s/front cabin. To achieve track tolerance mentioned in clause 3.13,
suitable hydraulic valves (servo control) shall be provided.
Page 6 of 39
 1404
2631744/2024/O/o PED/INFRA-1/RDSO

3.15 The machine shall be capable of carrying out on plain track, automatic lifting, leveling,
tamping and lining of 1000 sleepers or more in an effective hour of working in case of single
insertion and when tamping turnouts, it shall be capable of tamping one 1 in 12 turnout
complete with 10 sleepers one rail length on straight portion on the approaches of the
turnouts in an effective hour of working at the following machine parameters:

a) Squeezing time of 0.8 sec to 1.2 sec.

b) Squeezing pressure of 110 kg/cm 2 to 120 kg/cm 2 for plain track and 125 kg/cm 2
to 135 kg/cm 2 for turnouts.
c) Tamping depth upper edge of tool blade shall be15-20 mm below the bottom of
the sleeper.

However, the machine shall have the squeezing time range from 0.8 sec to 1.2 sec and
squeezing pressure range from 110 kg/cm2 to 135 kg/cm2.

The time shall be counted from start to finish of tamping work at work place. Stoppage of
work not attributable to machine shall be discounted. The setting up time and winding
uptime shall be measured and the total time taken by the two operations of setting up and
winding up of the machine together shall not exceed 10 minutes. The setting up time shall
be counted from the time machine arrives at site to the time work is started. The winding up
time will be counted from the time the work is stopped to the time machines starts moving
away from the work site. Dimensions of sleepers are given in Annexure–VI. The supplier
shall furnish the complete details of the tamping cycle of the machine, its timings and other
operational details to show the compliance to this performance parameter.

3.16 The machine shall be provided with suitable hydraulically operated compactors on both
sides to compact the shoulder ballast. It shall be possible to suitably retract the shoulder
ballast compactors near the OHE mast or signal posts etc.

3.17 The machine shall be capable of automatic leveling, lining and tamping of turnouts with
Cast Manganese Steel (CMS) and built-up crossing of angles 1 in 8.5, 1 in 12 and 1 in 16
laid on concrete sleepers (52 kg, 60 kg and wider) without dismantling the turnout.

3.18 The machine shall be capable of tamping, lifting and lining of track laid on pre-stressed
concrete sleepers with long welded rails, short welded rails and fish-plated rails as per
Annexure-VI. The normal sleeper spacing centre to centre in different track structures on
Indian Railways is 550 mm to 650 mm and the clear spacing between sleepers varying from
260 mm to 405 mm.

3.19 The maximum depth of concrete sleeper is up-to 235 mm. On Indian Railways, rail top to
sleeper bottom depth may vary from 365 mm to 425 mm. The machine, although having
zone of influence of tamping confined to approximately 150 mm depth below the bottom of
sleepers, shall effectively compact ballast depth ranging from 300 mm to 350 mm. There
shall be provision for step less adjustment of the penetration depth of tamping tools to suite
different types of rails and sleepers. The machine shall be provided with a mechanical
penetration assistance system to achieve full penetration even in caked ballast bed. The
tamping units shall be equipped with a vibration control system. The system shall increase
the mechanical induced vibration for easy penetration while lowering the tamping units.

3.20 For handling of engineering materials & equipment a suitable telescopic crane arrangement
may be provided at one end of the material platform. The crane shall be capable of lifting.
1.5 t load over front at such a minimum lifting radius up to 3000 mm that it is possible to
load & unload 60 kg CMS crossing, 6.5 m long 60 kg Rail, & concrete sleeper (details as
per annexure-VI) from machine to the Railway track below & vice versa. It shall be possible
to work with this crane in electrified sections of Indian Railways without taking power block.
Page 7 of 39
 1405
2631744/2024/O/o PED/INFRA-1/RDSO
Proper slings or any other equivalent arrangement required for picking up rails, sleepers or
crossings shall be supplied as part of the crane.

3.21 The crane operation shall be such that there is no infringement to overhead electric
equipment during crane maneuvering/extension/shortening and there is no infringement to
the Indian Railways Schedule of Dimensions-1676 mm gauge (BG), revised, 2004 with
latest corrigendum and up to date correction slips issued, on the adjacent track at 4265 mm
track centers. In case there is a possibility of boom getting lifted to infringe the overhead
electric equipment, suitable safety device to prevent such an eventuality shall be provided.

3.22 The working cabins of the machine shall be air-conditioned. The air-conditioning provided
shall be of robust industrial design capable of operating in highly dust laden environment.
However, the electronic equipment shall be so designed that it shall be able to work without
air conditioning under the climatic conditions described in clause 2.12 of the specification.

3.20 The machine shall be provided with a computerized unit for the overall control of its working
system for all possible track geometry. The system shall be so designed that for working on
tracks with pre-decided target geometry, the standard track geometry data as well as
correction values can be entered prior to work either directly on system or via USB, CD or
DVD. For working on tracks with unknown target geometry (precision mode), it shall be
possible to determine the correction values by making a measuring run and subsequent
geometry compensation of the recorded data considering obligatory point and constrains of
lifting and lining etc. The machine shall also be capable of correcting/smoothen alignment
of the track on curves by working in smoothing mode/compensation mode when theoretical
track geometry is either not known or not required to be known and when due to location of
track defects, the tracks slewing value are expected so large that they cannot be
implemented without additional measure and it is decided to smoothen the curve rather
than bringing it to the targeted/design profile. Interactive processing of the target profile by
the operator shall be possible. Track parameters shall be displayed in graphic as well as
text form on a colour monitor. Pre and post tamping graph shall be superimposed and also
it should be capable to display in tabular from at desired distance. It shall be possible to
guide the lifting and lining system of the machine continuously and automatically by this
unit. The machine shall be capable of measuring and recording the longitudinal level of both
rails, alignment of datum rail (versine), cross level (super elevation) and twist in real time
before and after the tamping by the machine. These parameters shall be displayed on
screen and its print out (printing arrangement to be provided) could be taken whenever
required. It shall also record progress vis - a - vis time and it shall be possible to take all the
above data on USB drive. The software shall be Windows based. The hardware shall be
sturdy for operations under conditions of shock, vibrations, dust, electromagnetic influences
from outside and interruption of power supply. The unit shall have adequate memory to
keep records of minimum 100 km track length of work performed; new track geometry
obtained and enables transfer of the data via USB CD or DVD as required.

3.21 In addition to the computer system provided on the machine for its own controls, the
machine shall be provided with an industrial quality heavy duty portable computer (Laptop-
tough book) for keeping record of overall aspects of working, spares management and
reporting. The software shall be window based. The hardware shall be sturdy for operation
under conditions of shock, vibrations, dust, electromagnetic influence from outside and
interruption of power supply. The detailed specifications of the laptop (tough book) are
enclosed as Annexure-VIII.

3.22 Important tamping parameters like datum rail, general lift, single insertion or double
insertion, design or smoothening mode, time of start and finish of work, squeezing
pressure, squeezing time, vibration pressure and tamping depth etc shall be shown on a
display in the working cabin. It shall have an inbuilt storage to store the above parameters
of minimum 100 hours of tamping work. The storage however shall not be less than 500
Page 8 of 39
 1406
2631744/2024/O/o PED/INFRA-1/RDSO
GB. It shall be possible to draw these data from the system itself after work via USB port on
a memory stick for the purpose of record.

3.23 A programmable logic control system shall be provided in the machine so that the work like
lifting, lining, tamping and work drive of machine will commence only when all conditions for
their working/movement are fulfilled.

3.24 The machine shall be equipped with GPS, GSM/GPRS based remote monitoring
capabilities for various track parameters and vital parameters of track machine. It shall also
have facility to interface with Human Machine Interference (HMI)/Display and various other
sensors. The data transfer unit shall be compatible with the Track Machine Management
System (TMMS) of Indian Railways.

3.25 In case of failure of the up and down cylinders of tamping unit, there shall be an
arrangement for lifting the all tamping units mechanically by lifting equipment like trifor/chain
pulley etc. Any other alternative arrangement for mechanically lifting tamping unit in such
failures may also be provided.

3.26 The machine shall be equipped with a centralized computer-based control and monitoring
system which shall monitor the health of machine working system such as engine (lubricant
oil pressure, temperature, rpm with engine running hours etc.) hydraulics (hydraulic oil
pressure in different units, temperature, oil level in tank etc.), pneumatic (pressure of main
reservoir, brake cylinder and others sections), electrical (charging/discharging rate, voltage
etc.). There shall be provision of recording and logging of machine working hours and such
gauge shall also be displayed on the monitor of the computer installed in operator cabin. All
these data shall be displayed on a monitor installed in working cabin and there shall be
facility to store these data for 100 Engine Running Hours. Minimum storage of 500 GB shall
be available for this purpose. Arrangement for providing 3G/4G 4G/5G internet connection
for sending data in soft format directly from the computer shall also be available for storage
of recorded data.

3.27 The machine shall be equipped with an electronic device for measuring and recording the
following track parameters in real time:

i) Alignment on minimum 7.2 m chord length

ii) Longitudinal level on minimum 3.6 m chord length
iii) Cross level difference and twist at every 0.6 m or less (twist shall be reported in
mm/m on 3.0 m base)
iv) Super elevation
v) Lifting value.

The hardware shall consist of a touch panel computer with flash disc and an ink-jet printer.
There shall be provision to fix threshold value of above parameters and it shall be possible
to draw reports to allow evaluations when threshold values are overstepped. Standard
deviations shall also be calculated in 200 m sections for the track parameters i.e alignment
of the reference rail, longitudinal level and twist. It shall have an inbuilt storage to store the
above parameters of minimum 100 hours of tamping work. The storage however shall not
be less than 500 GB for this purpose.

3.28 The AGC (automatic guiding computer) system/software shall be capable of recording pre
and post tamping track parameters i.e., unevenness, cross level, alignment in analogue
format at every 1 m interval. Also, the AGC (automatic guiding computer) system/software
shall be capable to work out the “standard deviation” (SD) of the track parameters before
and after tamping to assess the correct picture of the quality of work done by the machine.

Page 9 of 39
 1407
2631744/2024/O/o PED/INFRA-1/RDSO
3.29 The machine shall be capable to work in manual mode also in case of failure of
computer/software/display units along with provision of manual feeding with separate
display of required data. Necessary calculation chart shall be provided with each machine.

3.30 All inputs values like general lift, super elevation, tamping depth, versine etc. shall be also
displayed on the panel board in addition to display unit of AGC (automatic guiding
computer).

3.31 Tamping tools provided with machine shall be wear resistant and have carbide tips.

4.0 DIESEL ENGINE:

4.1 The machine shall be powered by diesel engines preferably indigenous with proven record
of service in tropical countries with wide service network in India. Robust construction and
low maintenance cost are of particular importance. Adequate allowance shall be made for
de-rating of diesel engine under the most adverse climatic conditions mentioned in clause
2.12. Manufacturer of diesel engines, proposed to be provided on vehicle, shall have
proven record of design manufacture & supply of engines for heavy duty industrial
use/locomotives application/track vehicles application/self-propelled railway rolling stocks
(with speed potential as needed for vehicle or more) application. In order to adhere to
pollution control norms, the diesel engine shall be electronically controlled emmissionized
engine with minimum compliance of tier 2 stage/UIC-II/BS-II BS-VI standard/the emission
regulation standards set by Indian regulatory bodies.

4.2 The supplier shall furnish the engine information regarding make and model of the engine
proposed to be used and details of agency which will provide after sales service support
and availability of spares in India, details of diesel engine and its controls to assess its
conformity with the engines already operating on track machines on Indian Railways. If the
machine design incorporates an engine not already operating with the purchaser, the model
of the engine is liable for change as per the technical requirements and the maintenance
logistics with the purchaser after technical negotiations with the supplier. Nothing extra shall
be payable on this account.

4.3 High speed diesel oil to Indian standard specification shall normally be used. A minimum
fuel tank capacity sufficient for continuous operation for eight hours but not less than 1400
liters shall be provided.

4.4 Sight glass type fuel measuring gauge preferably of full height shall be provided on the fuel
tank.

4.5 For starting the engine, storage batteries of well-known indigenous make with wide service
network in India shall be provided. The engine shall normally be push/pull button start type
or key start type. A battery management system to be provided. It should report too low
battery voltage to the machine operator and protect the battery from deep discharge. The
capacity of the battery must be selected in such a way that, in the event of a battery charge
failure and a 50% discharged battery, the machine should be able to work for 30 minutes
with all safety and operational functions. There shall be also an indicator for charging of
both main and programmer battery displayed on the panel board.

4.6 Since the engine has to work outdoor under extreme dusty conditions, the air intake system
shall be designed suitably so as not to allow dust through air intake system.

4.7 There is a likelihood of dust deposition over the engine body and surrounding area over the
spilled lubricants. These shall be easy to access for daily cleaning and routine
maintenance. For water cooled engines, the engine cooling radiator shall be easily
Page 10 of 39
 1408
2631744/2024/O/o PED/INFRA-1/RDSO
accessible for regular maintenance like checking the coolant level and topping up of the
coolant whenever necessary. Such maintenance activity shall not require the staff to climb
up the machine roof. In case, air cooled engines are proposed by the supplier, maintenance
equipment for cleaning and maintenance of the air-cooling fins shall be provided by the
supplier along with the machine.

4.8 The engine parameter monitoring gauges like temperature, rpm, engine running hour and
lubricant oil pressure shall be direct reading type mounted on the engine backed up by
electrical/mechanical gauges in the operator‟s cabin showing the absolute readings along
with safe limits suitably colored. There shall be audio visual warning (safety mechanism) to
the operators in case of any of these parameters (low lubricant oil pressure and high
temperature) exceeding the safe limit and also to shut down engine automatically.

4.9 Suitable and rugged mechanism shall be provided to start the prime mover at minimum/no
load and gradual loading after the start of the prime mover. The engine shall be mounted on
suitable anti-vibration mountings.

4.10 The engine shall have electronic control module (ECM) or similar arrangement for taking
out operating parameters on real time basis such as rpm, load, fuel oil pressure, fuel
consumption, temperature, pressure and diagnostic data as well as trip and historical data.
These data shall be displayed and stored on a centralized computer and monitoring system
as mentioned in clause 3.26. It shall also be possible to transfer these data on USB device
through the centralized computer-based control.

4.11 The engine shall be enclosed in a weather protective, sound and dust resistant enclosure to
minimize engine noise and to prevent oozing out of oil spills etc. from engine area to the
exhaust manifold and adjacent machine components, hoses, electrical cables fittings as a
protection against fire. All doors on the enclosure shall be strategically located in area as to
allow ease of maintenance of the engine and allow good access to and visibility of
instruments, controls, engine gauges, etc. Sufficient louvers shall be provided to allow the
total engine cooling air requirements used in this application.

4.12 The tenderer shall supply engine driven minimum two alternators (28V/55A) of adequate
capacity as standard accessory for charging battery for engine cranking, lighting and other
controls.

5.0 DRIVE MECHANISM:

5.1 The machine shall be provided with an efficient traction drive system for traction during the
operation. It shall be equipped with separate power transmission circuits for high-speed
travelling in traveling mode and slow cyclic movement in working mode.

5.2 The driving mechanism for travel drive shall be rugged to perform satisfactorily during the
life cycle of the machine. The machine‟s driving system shall be through diesel electric or
hydrodynamic/hydrostatic coupled power transmission with shift arrangement capable of
achieving full speeds in travel mode in both the directions. The supplier shall submit the
self-certification for Electromagnetic compatibility (EMI/EMC) of the machine. test certificate
for interfering with signal and telecom equipment shall be submitted.

5.3 The driving mechanism, in working mode, shall be adequately designed to handle the
acceleration and braking forces at each tamping cycle. A suitable synchronization circuit to
control the synchronization of lifting/lining/tamping process with the machine drive/braking
system in working mode shall be provided to prevent any damage to the machine systems
on account of non-synchronization.

Page 11 of 39
 1409
2631744/2024/O/o PED/INFRA-1/RDSO
5.4 The tenderer shall provide the necessary technical details including circuit diagrams
and detailed technical specifications of all mechanical, hydraulic, pneumatic
electrical/electronic parts with make and model if using from open market to confirm the
above requirements.

5.5 Adequate control equipment including gauges, instruments and safety devices to monitor
driving and working performance of machine shall be provided in working and driving
cabins near operator‟s seat. Solenoid valves shall be provided near linkage assembly, for
indication, flow control and carrying out necessary adjustment in the field.

5.6 To the extent possible hydraulic and pneumatic component/assembly shall be fixed at
suitable location preferably on the side frame of the machine so as to avoid the need of
going on top of the machine for day-today maintenance schedules.

5.7 The pneumatic circuit shall be provided with air dryer, air lubricator, water separator and
safety valves for the smooth working of pneumatic components.

5.8 The machine shall be equipped with hot axle sensor for each axle and also adequate safety
circuit such that if any unit/part which may endanger the safety are unlocked or the air
pressure in brake circuit is less than 5 bar, the machine shall not move during run drive.
The indication of hot axle, locking and unlocking of all units shall be displayed in the cabin.

5.9 Onboard system for online filtration and monitoring the quality of hydraulic oil in hydraulic
circuit and filtration as required shall be provided. The gauge shall clearly indicate if the
hydraulic oil is contaminated beyond the permissible limits and requires immediate
replacement.

6.0 COOLING SYSTEM:

6.1 The cooling system shall be efficient and designed for a maximum ambient temperature of
55°C. Supplier shall note that the machine shall be working under extreme dusty conditions
and the cooling mechanism shall be maintainable under these conditions.

6.2 Adequate heat transfer arrangement shall be designed and provided so that under extreme
heat conditions as mentioned in 2.12 above, the system oil temperature does not go
beyond range specified by the supplier.

7.0 BRAKES:

7.1 The machine shall be equipped with compressed air brake system which shall apply brake
equally on all wheels and provision shall be made to connect air brake system of the
machine to that of coach/wagon when the machine is hauling them. Fail safe braking
mechanism system shall be provided so that any failure of brake circuit, will result in
automatic application of brake. The brakes shall be protected from ingress of water, grease,
oil or other substances, which may have an adverse effect on them. The brake lining shall
be suitable for high ambient temperature of 55°C. The force required for operating the
brake shall not exceed 10 kg at the handle while applying by hand and 20 kg on the pedal,
when applying by foot.

7.2 Machine shall be equipped with suitable arrangement of braking so that while attached in
train formation, as last vehicle machine can be braked by traction vehicle having
compressed air braking system. In addition, the machine shall be equipped with suitable air
brake system in the driving cabins so that the wagon or coach being hauled by machine
can be braked.

Page 12 of 39
 1410
2631744/2024/O/o PED/INFRA-1/RDSO
7.3 There shall be provision of mechanical emergency brake application using the compressed
air in the machine either travelling alone or coupled with the coach/wagons, in addition to
the normal braking system of the machine. The emergency braking distance (EBD) of the
machine on the Indian Railways Track, at the maximum design speed on level track shall
not be more than 600 m. Design calculations for the braking effort and EBD at the
maximum design speed of the machine on level track & at falling grade of 1 in 33 shall be
provided by the supplier. Brake design details are to be submitted as per Annexure-IX.

7.4 The spring loaded pneumatic parking brake shall be provided as per RDSO specification
no. C-K 408 with latest amendments. Mechanical brakes shall also be provided in addition
for use as parking. There shall be also an easy arrangement to release the parking brake in
case of emergency.

7.5 Clearly visible brake lights shall be provided at both the ends of the machine, which will be
automatically operated when brake is applied and switched off when brake is released. This
will be required to alert the operator of machine following this machine when the machines
are working in groups.

7.6 Stand-alone VCD of approved make conforming to RDSO specification no. MP-0.34.00.04
(Rev-04), Dec-2008 shall be provided.

7.6 An annexure containing functional requirement on the Brake system of the vehicle is
attached as annexure XI.

8.0 HORNS, HOOTERS, SAFETY SWITCHES AND EMERGENCY BACKUP SYSTEMS:

8.1 The machine shall be provided with dual tone (low tone & high tone) electric/pneumatic
horns facing outwards at each end of the machine at suitable locations for use during
travelling to warn the workmen of any impending danger. Control/switch shall be provided in
close proximity to the driver permitting the driver to operate either horn individually or both
horns simultaneously. The horns shall be distinctly audible from a distance of at least 400 m
from the machine and shall produce sound of 120-125 dB at a distance of 5 m from horn
(source of sound). The higher tone horn shall have fundamental frequency of 370 ±15
hertz. These horns shall be operated by means of push buttons provided in the cabins.

8.2 Jacks, pullers, tirfor and other such other safety equipment specific to the machine for
restoring failed units of the machine during working, shall be provided on the machine.

8.2 Machine shall be provided with emergency backup system to wind up the machine in the
event of failure of prime mover or power transmission system of the machine. The
emergency backup system shall be able to be operated manually also.

8.3 Pneumatically/electrically operated hooters capable of producing sound of intensity

between 105-110 dB(A) at a distance of 5 m (when measured in still air in a closed room)
with variation in intensity of sound not more than 5 dB(A) shall be provided. The hooters
shall be provided facing outwards at each end of the machine at suitable locations,
operated by means of push buttons provided in the cabins to warn the staff working
on/around the machine about approaching train on adjoining track. Additionally switches for
such hooter shall be provided outside on the machine frame and near the both side exit
gates so that it can be operated by staff present at work site near the machine. The hooter
shall also be operable by remote switch at a distance of at least 300 m from the hooter.

8.4 Adequate numbers of safety stop/switches shall be provided all around so that in case of
any danger to worker as well as hitting of any obstructions by working unit like signaling
cable, joggle fish plate etc, during work, the operator can be warned or the machine can be
stopped immediately. Safety stop indication should be displayed/glow in operator‟s cabin.
Page 13 of 39
 1411
2631744/2024/O/o PED/INFRA-1/RDSO

8.5 In addition, separate electric horns with push bottom type switches shall be provided at
suitable locations in all cabin(s) and on machine body for communication between the
machine staff about infringement/malfunctioning or any other trouble.

9.0 HOOKS AND BUFFERS:

9.1 The machine shall be fitted with transition coupling as per RDSO specification no. 56-BD-07
RDSO/2009/CG-22 with latest revision along with side buffers to RDSO drawing no.
RDSO/SK-98145 with latest alteration on both ends for coupling it with coach/wagon or
other vehicles and running it in train formation as last vehicle and for attachment with the
coach, locomotives and wagon.

10.0 SUSPENSION SYSTEM:

10.1 The suspension system shall be preferably of two-stage type with suitable spring and
damping arrangement. Springs for primary and secondary suspension shall be designed to
cater for actual service conditions. Effective measures shall be adopted to minimize the
weight transfer while starting, stopping and during runs.

11.0 HEAD LIGHT, FLASHER LIGHT, MARKER LIGHT AND OTHER LIGHTING
ARRANGEMENTS:

11.1 The electrical equipment to be provided shall conform to relevant standard specifications
and shall be suitable for Indian climatic conditions. The machine shall be equipped with
twin beam LED headlight assembly, conforming to RDSO specification no.
RDSO/2017/EL/SPEC/0134 (Rev-1 Rev.02) with latest amendments ensuring a light
intensity of 3.2 lux 4.8 lux at ground level at track centre at a distance of 305 m. away on a
clear dark night, at each end and with two front and rear parking lights, which can be
switched to red or white according to the direction of the travel. Powerful swiveling
floodlights shall also be provided to illuminate the working area (10 meter radius) sufficiently
bright for efficient working during night. In addition minimum eight power point locations (24
volt DC/15 amp socket) shall be provided on outside frame of the machine two in front, two
in rear and two on both sides for providing lighting arrangements during night working.
Preferably electric power of 24 V (maximum up to 110 V) shall be used for operation of any
electrical circuit.

11.2 In addition to swivelling floodlights mentioned in para 11.1, powerful swivelling floodlights
shall also be provided at each corner of the machine to illuminate the surrounding area
sufficiently bright for efficient working during night. In addition minimum twelve power point
locations (230/250 V AC socket) shall be provided on outside frame of the machine two in
front, two in rear and four on both sides for providing lighting arrangements during night
working. Suitable light fittings shall also be provided which will be used during night working
otherwise it should be kept at a secure place provided on the machine. The power supply to
all the fittings and sockets operated with 230/250 V AC shall be fed by welding plant as
mentioned in clause no. 15.6. Illumination survey or light assessment or Lux level survey
report shall be submitted by the supplier.

11.3 The amber colour LED based flasher lights producing not less than 500 lux at 1 m and 55
lux at 3 m in line measurement in axial direction from flasher light to RDSO Spec No.
ELRS/SPEC/LFL/0017 (Rev-1) of Sept-2004 or latest shall be provided at both ends on the
machine to give indication to the train arriving on other line about any impending danger.

11.4 The machine shall be provided with marker light to RDSO specification no.
ELRS/SPEC/PR/0022, (Rev-1) October‟ 2004 or latest.

Page 14 of 39
 1412
2631744/2024/O/o PED/INFRA-1/RDSO
12.0 CABINS:

12.1 The machine shall be equipped with fully enclosed sound and heat insulated cabins with
safety glass windows. at Both ends and working cabins shall be air conditioned for dust free
atmosphere. However, the electronic equipment shall be so designed that it shall be able
to work without air conditioning under the climatic conditions described in clause 2.12. The
air conditioner shall be of robust, industrial design capable of operating in highly dust laden
environment. In view of the high ambient temperature prevailing in India, special attention
shall be paid to free circulation of air and ventilation in the driver‟s cabin. The air-
conditioning units shall not be roof and under-frame mounted for safety and maintenance
purpose. It shall be possible to have a clear view of the track ahead while driving the
machine in both the directions from the cabins at either end. The cabin layout shall be such
that, before leaving the machine, the operating staff has full view on both the sides, to avoid
any danger to them from trains on the adjacent track. Additional driver‟s cabins shall be
provided if the view while driving is not clear for safe travel in both directions. The design of
cabin shall be as per UIC CODEX-651.

12.2 The gauges, warning panel, instruments and control panel shall be suitably located in the
operator‟s cab so that they can be observed by the operator without undue fatigue. Screen
wipers preferably operated by compressed air or electricity shall be provided on the wind
screen.

12.3 The operator‟s cabin shall be ergonomically designed to have easy access to all the
controls. The operator shall have a full view of the working area from the operating seat to
have a full control over the work.

12.4 Suitable number of fire extinguisher (dry chemical type) shall be provided in the cabins. The
chemicals used for extinguishing fire by such fire extinguishers shall not chemically react
with electronic equipment/components, PCBs, cables etc.

12.4 The machine shall be provided with well-designed adequate space for keeping the tools
and spares required for onsite repair of the machine to attend the breakdowns and other
working requirements.

12.5 Necessary inter-communication system shall be provided inter-connecting all the cabins
and should be so oriented that the operator, sitting in either cabin/working cabin, can
distinctly hear the conversation and shall also be the provision of recording the
conversation for inter-communication system. The volume control adjustment (preset) of
inter-communication system shall be provided on amplifier (PCB).

12.6 The machine shall be equipped with speed indicator and recording equipment of range
between 0–120 kmph 0–160 kmph for recording the speed of the machine in real time
basis. The equipment shall conform to RDSO specification no. MP-0-0.3700-07, Rev-07,
August, 2017 or latest. The recorded data shall be retrievable on computer through memory
card/pen drive. It shall be provided in the driving cabin at suitable place and recording
system should have sufficient memory to keep the speed record of minimum 15 days which
should always be stored for retrieving as per requirement.

12.7 The electric supply in the cabin for operation of electrical instruments, gauges etc. shall not
be more than of 110 V.

12.8 Operators cab camera with recording facility & voice logger shall be provided.

12.9 All metallic parts of the entire machine including bogies, superstructure along with electrical
equipment shall be integrated electrically through wheels to rail and as per IEC60950-1:
2005 to ensure proper earthing of the machine.
Page 15 of 39
 1413
2631744/2024/O/o PED/INFRA-1/RDSO

12.10 For prevention of fire in the machine suitable materials shall be used for construction of
interiors as well as exteriors of the cabin and for machine components. Proper design
layout, protective device and prevention measures for outbreak of fire shall be ensured. For
fire prevention “Code of Practice for Prevention of Fires on DMUs” conforming to document
no. CMI-K 402(Rev-1) with latest amendments shall be suitably followed as guidelines.

12.11 All the cables used in the rolling stock are compliant to BS6853/EN45545 Standard with
hazard level HL-2 for chair car. Fire survival cables shall be used in PA Lines, emergency
brake loop and critical control system. All other cables shall be fire resistant with improved
fire performance and high resistant to temperature.

12.12 All electrical wiring in the machine shall be done with e-beam cables conforming to RDSO‟s
Specification No ELRS/SPEC/ELC/0019 Rev.-3 dated 28.02.2017 with latest amendment.

12.13 Optical fiber based linear heat detection (LHD) system should be provided wherever there
are bunching of cables. LHD system works to determine the presence of a localized
temperature excursion against varying background temperatures.

12.14 The machine shall have automatic fire/smoke detection systems. This shall be capable of
detecting a smoke/fire in machine. On detection of a possible smoke/fire by means of
suitable detection system, the system shall have different levels of response to be finalized
at design stage.

13.0 CHASSIS AND UNDER-FRAME:

13.1 The chassis shall be of standard welded steel sections and of steel sheets, so as to permit
transportation of the machine in train formation without endangering safety of the train. The
under frame shall be constructed with rolled steel sections and/or plates and shall be
designed to withstand a horizontal squeeze load of 102 t at CBC rear stop or 51 t at each
buffing point without any permanent distortion. The under frame shall be sufficiently robust
for safe travel of the machine in train formation and not necessarily as the last vehicle.

13.2 There shall be provision of properly exhibited/conspicuous jacking and lifting points on the
machine under-frame for helping in quick handling of the crane in case of
derailment/accident as well as during maintenance at workshop. The jacking and lifting
points shall be obstruction free and easily accessible, so that jacks can be fitted/placed
conveniently. There should be no any rigid unit along the rail up-to 350 mm from wheel
tread and 525 mm above rail level.

13.3 Suitable capacity of jacks along with hydraulic pumps, aluminum beams, and other
accessories shall be provided for lifting and side slewing for re-railing of the machine in
case of derailment.

14.0 SAFETY FEATURES:

14.1 Provision for protective earthing against electrical hazard shall be in line with EN 50153:
Railway applications - Rolling stock - Protective provisions relating to electrical hazards. All
electrical equipment shall be provided with essential interlocks & keys as may be adequate
to ensure the protection of the equipment and the safety of those concerned with its
operation and maintenance.

14.2 The protective earth connects all metallic parts (e.g. apparatus housing, machine body,
work equipment) to the earth potential. To protect the axle bearings from current flow, the
current is transmitted to the wheel set via earth brushes. The earth brushes shall be

Page 16 of 39
 1414
2631744/2024/O/o PED/INFRA-1/RDSO
arranged in such a way that protective earthing via two wheels is ensured even in the case
of tracks insulated on one side. The earthing concept shall be documented.

14.3 Functionally related loads are to be protected by circuit breakers in order to keep the effects
of faults low and to facilitate fault location.

14.4 Stand-alone vigilance control device (VCD) of approved make conforming to RDSO
specification no. MP-0.34.00.04 (Rev-04), Dec-2008 shall be provided.

14.5 Suitable number (not less than 6) of fire extinguisher (dry chemical type) shall be provided
in the cabins. Easily accessible fire extinguishers are to be installed in the cabins. The
exact positioning is determined within the framework of the interior concept. The chemicals
used for extinguishing fire by such fire extinguishers shall not chemically react with
electronic equipment/components, PCBs, cables etc.

14.6 The fire protection on machine shall be designed and constructed in accordance with EN
45545.The applicable Hazard level will be HL 2, the supplier shall furnish the relevant fire
load calculations in hard as well as in soft copy. One set shall be sent to the
Principal/IRTMTC, Allahabad, one set to be sent to PED/Infra-1, RDSO, and Lucknow, one
set to EDTK (MC)/Railway Board and one set to Director General/IRICEN/Pune along with
supply of first machine.

14.7 The machine shall have automatic fire/smoke detection systems. This shall be capable of
detecting a smoke/fire in machine. On detection of a possible smoke/fire by means of
suitable detection system, the system shall have different levels of response to be finalized
at design stage.

14.8 All electrical wiring in the machine shall be done with e-beam cables conforming to RDSO‟s
Specification No ELRS/SPEC/ELC/0019 Rev.-3 dated 28.02.2017 with latest amendment.

14.9 Two nos. 50 t manually operated hydraulic lifting jack, with more than 300 mm traversing
facility suitable to lift the machine frame at lifting point, should be made provided to meet
out the urgency. Also a hydraulic hand pump unit should also be provided to operate any
other emergent operation of hydraulic cylinders and other such equipment specific to the
machine for restoring failed units of the machine during working, shall be provided on the
machine.

14.10 Signal exchange light (signal flashing scheme) similar to Vande Bharat for exchanging
signal shall be provided in the machine.

14.11 A clutch system should be provided to disengage all hydraulic pumps in case of bursting of
hydraulic hoses fitted in pumps.

15.0 TOOLS AND INSTRUCTION MANUALS:

15.1 Each machine shall be supplied with a complete kit of tools required by the operator in
emergency and for normal working of the machine. The list of tools to be provided shall also
include all tools necessary for maintenance and repair of the entire machine including
specialized equipment. All special tools shall be listed and catalogued illustrating the
method of application. The tenderer shall along with his offer submit the list of tools to be
supplied along with each machine. The list can be modified to suit the purchaser‟s
requirement, while examining the offer.

15.2 Detailed operating manual, maintenance and service manual, user manual indicating
capabilities of machine, prepared in English language with colour and four hard copies &
soft copies of each of the same shall be supplied with each machine.
Page 17 of 39
 1415
2631744/2024/O/o PED/INFRA-1/RDSO

15.3 The supplier/manufacturer shall also supply diagrams in hard copies & soft copies of
electrical, hydraulic, pneumatic and electronic circuits used on the machine. Trouble
shooting diagram/table shall also be supplied. In addition, the supplier shall provide
dimensional drawings with material description of items like rubber seals, washers, springs,
bushes, metallic pins etc. Main features such as type, rpm & discharge etc of items like
hydraulic pumps, motors shall be furnished by the tenderer. These shall be specially
prepared in English language and four hard copies & soft copies of these shall be provided
with each machine. The tenderer shall furnish the details of such other bought out
components/assemblies.

15.4 The tenderer shall along with his offer, submit the list of tools, manuals, circuit diagrams
and other technical literature/drawings in English language to be supplied along with each
machine as above, for operation, servicing, maintenance, assembly overhauling, periodic
overhauling and troubleshooting guides/manuals. The list can be modified to suit the
purchaser‟s requirement, while examining the offer.

15.5 While offering the machine for first inspection, the supplier shall submit one copy of
complete technical literature in English language including operation, service and
maintenance manual/instructions and complete electrical, electronic hydraulic & pneumatic
circuit diagrams, troubleshooting charts, component drawings/description and other
relevant technical details for keeping as reference document for the inspecting officer.

15.6 One portable diesel operated D.C. welding plant (with the provision of auxiliary output of
minimum 2.5 KW, 230 V AC for lighting) of reputed make (preferably made in India) with a
minimum 5 KVA capacity capable of welding up to 5 mm. electrode (dia) at 60% duty cycle
shall be supplied. Sufficient cable or lead shall be provided with the welding plant for day to
day repairing of machine and its wearing parts. The diesel tank capacity shall be not less
than 15 liters.

15.7 The tenderer shall provide detailed technical drawings and specifications of wheels and
axles used on the machine along with detailed code of procedure for ultrasonic testing
axles of all types and test report of wheels shall be submitted along with other documents.
The above details shall be provided in four sets with each machine.

15.8 One set of all the manuals and diagrams shall also be sent to the Principal/IRTMTC/
Allahabad, one set for Chief Workshop Manager (Track Machines), CPOH Workshop, PO.
Dhoomanganj, Prayagraj -211011, one set for Chief Workshop Manager (Track Machines),
CPOH Workshop, South Central Railway, Rayanapadu, Vijaywada, Dist.-Krishna, Andhra
Pradesh-521241, one set for Chief Workshop Manager (Track Machines), CPOH
Workshop, Eastern Railway, Bhutbagan Railway Colony, Kanchrapara, P.S: Bizpur, P.O.:
Kanchrapara, West Bengal-743145, one set for Chief Engineer. C.P.O.H, Western Railway,
Divisional Office, Near Chamunda Mata Mandir, Naroda Road, P.O. – Saijpur Bodha,
Ahmedabad-382345,one set to PED/TMM/RDSO/Lucknow, one set to EDTK (MC)/Railway
Board and one set to Director General/IRICEN/Pune along with supply of first machine of
similar group. In case, there is any subsequent amendment in above documents based on
field performance, the amendment/amended documents shall also be sent to above
mentioned authorities.

15.9 A draft copy of all documents to be supplied with the machine shall be sent 3 months in
advance of inspection of the first machine to RDSO for their review regarding adequacy and
manner of detailing. Necessary modifications and further detailing as per RDSO‟s
comments shall be carried out and compliance shall be reported to RDSO as well as the
Inspecting officer of the first machine.

Page 18 of 39
 1416
2631744/2024/O/o PED/INFRA-1/RDSO
15.10 First aid box with prescribed medicines & other items shall be supplied with each machine
and first aid box shall be mounted at an appropriate place.

16.0 SPARE PARTS:

16.1 The tenderer shall quote, apart from main equipment, separately for the mandatory spares
as well as for recommended spares required for two years i.e., working for about 2000 hrs
of operation along with description, part number, quantity, cost, whether imported or
indigenous. The expected life of components/spare parts shall be advised along with their
condemning limits.

16.2 The supplier shall be responsible for the subsequent availability of spare parts to ensure
trouble free service for the life of the machine (20 years). It is preferred that the spares shall
be stored in India and will be available at short notice say maximum within a month.

16.3 For indigenous parts and brought out components and assemblies, the source (original
equipment manufacturer‟s reference and part no.) and other relevant technical details shall
be supplied while offering the first machine for inspection.

17.0 MAKER’S TEST CERTIFICATES:

17.1 Copies of maker‟s certificate guaranteeing the performance of the machines shall be
supplied in duplicate along with the delivery of each machine.

18.0 OPERATORS:

18.1 The number of operators and allied staff for working of the machine under normal working
condition shall be indicated, specifying their duties and minimum qualifications.

19.0 OPTIONAL EQUIPMENT:

19.1 Tenderer is expected to quote for optional equipment separately, if any for each item giving
the advantages/functions of such optional equipment. Tenderer shall also indicate whether
such equipment is already in use on machines elsewhere indicating the user Railway
system.

20.0 WARRANTY:

20.1 The machine shall be warranted for 1200 effective working hours or 18 months from date
of commissioning and proving test of equipment or 24 months from date of delivery at
ultimate destination in India whichever shall be earlier. Effective working hours for this
purpose will be traffic block time during which machine is deployed for tamping work.

Should any design modification be made in any part of the equipment offered, the warranty
period of 18 months would commence from the commissioning and proving test of
equipment for the purpose of that part and those parts which may get damaged due to
defects in the new replaced part. The cost of such modification shall be borne by the
supplier.

21.0 INSPECTION OF THE MACHINE:

21.1 While inspecting the machine before dispatch from the supplier‟s premises, the inspecting
officer to be nominated by the purchaser shall verify the conformity of the machine with
respect to individual specification as above. The machine‟s conformity/non-conformity with
respect to each item shall be jointly recorded, before issue of the inspection certificate and
approval for dispatch of the machine as per Annexure–III enclosed.
Page 19 of 39
 1417
2631744/2024/O/o PED/INFRA-1/RDSO

21.2 Following arrangements shall be made by the supplier/manufacturer at the inspection

premises for carrying out inspection of the machine by inspecting officials:

 Machine shall be stabled on straight & level BG track. The length of the track shall
be at least 10 m more than buffer to buffer length of machine.

 In order to check maximum moving dimensions in cross section, a sturdy frame of

Indian Railways maximum moving dimensions shall be provided by the
manufacturer and passed over the machine holding it perpendicular to track, centre
aligned with track centre. Adequate arrangements shall be made to the satisfaction
of inspecting official.

21.3 The following documents shall be provided to the Inspecting Officer (IO) at least 30 days
before the proposed date of inspection.

i) One copy of complete technical literature mentioned in clause 15.0, in English

language, including operation, service and field maintenance manuals/instructions
user manual and complete electrical, hydraulic and pneumatic circuit diagrams,
trouble shooting charts, component drawings/description and other relevant
technical details as a reference documents in soft & hard copies for the inspecting
officer.

ii) Cross section of the machine super imposed on Indian Railways maximum moving
dimensions envelope.

iii) Clause by clause comments of the manufacturer for review. Comments shall state
manufacturer‟s conformity of compliance of each of the requirement stated in each
clause of the specification, elaborating where necessary the details/manner in which
the requirement has been complied. The proforma for the clause-wise comments is
given below:

Clause Clause no. Comments of Comments of

Supplier/manufacturer Inspecting Officer

iv) Manufacturer‟s internal quality inspection report of the machine.

v) Manufacturer‟s quality certificate and/or test reports for bought out assemblies/sub-
assemblies with serial number wherever applicable.

vi) Draft inspection report shall be prepared by the manufacturer, containing all
annexures mentioned at clause 21.4.

vii) Details of arrangements made for checking maximum moving dimensions for
approval.

viii) Illumination survey or light assessment or Lux level survey report.

Supplier will incorporate amendments/further clarification in the above documents to the

satisfaction of the Inspecting Officer keeping in view the Inspecting Officer‟s comments, if
any.

21.4 List of documents to be annexed in the draft inspection report shall include:

Page 20 of 39
 1418
2631744/2024/O/o PED/INFRA-1/RDSO
i) Maker‟s test certificate.
ii) Manufacturer‟s internal quality inspection report.
iii) Quality certificates of bought out assemblies/sub-assemblies.
iv) Cross section of the machine super imposed on the Indian Railway maximum
moving dimensions (IR MMD).
v) Vogel‟s diagram.
vi) List of spare parts to be dispatched along with the machine.
vii) List of tools to be dispatched along with the machine.
viii) List of manuals, drawings, spare parts catalogues, etc. to be dispatched along with
the machine, duly indicating the number of sets of each.
ix) Manufacturere‟s certificate on standard followed for design of wheels and axles
against clause 2.8 to 2.10.
These above documents in soft & hard copies shall be part of final inspection report.

22.0 TRAINING AND SERVICE ENGINEERS:

22.1 The supplier shall provide at his own expense the services of competent engineers during
the warrantee period for warranty related issues. The service engineers shall be available
for the commissioning of the machine for regular service. E-Learning courses module shall
be arranged for imparting training to railway operators. In addition, the service engineer
shall provide hands on training to railway staff in calibration, operation, repairing and
maintenance of the machine in field to make them fully conversant with the machine. The
engineers shall also advise the Railways on appropriate maintenance, testing, operating,
repair and staff training facilities that are necessary for the efficient performance of the
machines.

22.2 During the warrantee period of the machine, the supplier must ensure trouble free
availability of the machine in good working condition for at least 90% of the time and
accordingly they must ensure availability of spares & services of competent service
engineers at prompt disposal of user railways.

23.0 ACCEPTANCE TEST:

23.1 In addition to verification of the various items of specifications covered earlier, the following
tests shall be carried out in India at the purchaser‟s premises by the purchaser‟s nominee at
the time of the commissioning of the machine. The pre commissioning tests shall be
completed and the machine shall be commissioned within 90 days of its arrival at the
premises of the final consignee.

23.1.1. The dimensional check of loading gauge, i.e., maximum moving dimensions, buffer
heights, clearances, length of machine, bogie distance and clearance on curves
etc.

23.1.2. Testing for negotiability of 10° curves and 1 in 8.5 turnouts.

23.1.3. Construction and engineering of the machine and its ability to perform all the
functions as laid down in the specification.

23.1.4. Illumination for the working and surrounding area of the machine, sufficiently
illuminated for efficient working during night as per clause no. 11.2.

23.1.5. Actual output and performance test to be conducted on the first machine.

These tests shall be conducted under field conditions on Indian Railways. An

electrified section shall be chosen for this test.

Page 21 of 39
 1419
2631744/2024/O/o PED/INFRA-1/RDSO

The general conditions of tests shall be as follows: - Refer clause 3.0

i) Machine crew shall be either trained personnel of Indian Railways or the staff of
the supplier.
ii) Dry weather, ambient temperature between -15°C to 550 C.
iii) Straight track or curve with radius not less than 175 m.
iv) Gradients up to 1 in 33 (3%)
v) Straight track with gradient up to 5 per thousand 1 in 200.
vi) Rails and sleepers in good conditions and properly fastened.
vii) Concrete sleepers.
viii) Clean ballast cushion up to 150 mm in sufficient quantity below the bottom of the
sleepers and generally not cemented.
ix) LWR track.
x) Regular sleeper spacing of 550 mm to 650 mm with a tolerance of ± 20 mm on
straight track.
xi) Formation good.
xii) General lift up to 20 mm.
xiii) Maximum slew up to ± 10 mm.

Test to be conducted:

At the parameters specified by the tenderer against clause 3.15 the machine shall be
capable of carrying out on plain track, automatic lifting, leveling, tamping and lining of 1000
sleepers or more in an hour of effective working in case of single insertion. When tamping
turnouts, it shall be capable of tamping one 1 in 12 turnout complete with 10 sleepers one
rail length on straight portion on the approaches of the turnouts in an effective hour of
working. Stoppage of work not attributable to machine shall be discounted. The time shall
be counted from the time the machine arrives at the place of work to the time it is ready to
start back from work after winding up operation. The setting up time and winding uptime
shall be measured and the total time taken by the two operations of setting up and winding
up of the machine together shall not exceed 10 minutes.

24.0 Should any modification be found necessary as a result of the tests, these shall be
carried out by the supplier at his own expenses.

25.0 SPEED CERTIFICATE:

25.1 Provisional Speed Certificate

Whenever a new rolling stock is introduced in Indian Railways, a provisional speed

certificate is issued by Research, Design and Standards Organization (RDSO) of Indian
Railways at Lucknow, based on certain design parameters of the machine. Final speed
certificate of the machine is given after conducting detailed oscillation trial of the machine,
which shall be a time taking process. Therefore, issue of provisional speed certificate for
the machine becomes a necessity and based on the same the approval of running of the
machine on Indian Railways track is taken from Commissioner of Railway Safety.

For issue of provisional speed certificate, following actions are required to be taken by the
suppliers.

a) Current supplier, whose models are approved:

The supplier shall give details of the model, year of introduction in Indian Railways,
details of speed certificate issued etc. The supplier shall certify that no change has
taken place in the model being offered with respect to design of under frame i.e.,
Page 22 of 39
 1420
2631744/2024/O/o PED/INFRA-1/RDSO
suspension system/arrangement, wheel & axle assembly, bogie braking arrangement,
loading pattern of the machine etc and the distribution of axle loads, lateral forces, un-
sprung mass, tractive effort and braking force coming on rail and they remain the
same. If there is any change in any of the above parameters action shall be taken as
detailed in Para (b) below.

b) Current Supplier, whose models are not approved/ or new:

As soon as the supplier completes the design of the machine as per specification, the
technical details as per Annexure (IV & V) which in no case shall be more than six
months from signing of contract, shall be supplied to Track Machine and Monitoring
Directorate of RDSO of Indian Railways at Lucknow, for processing of provisional
speed certificate for the machine so that it can be permitted to move on track on case-
to – case basis, more technical details (other than mentioned in Annexure (IV & V))
can also be asked for issue of provisional speed certificate for the machine .The firm
will also submit the technical details as per pro-forma placed at Annexure-X. The
supplier shall submit the dynamic simulation report of the machine on his own cost on
professional track vehicle simulation software. The machine shall have to fulfil the
acceptance criteria specified at Annexure-II.

c) New supplier, whose models are new:

The technical details shall be supplied as detailed in para (b) above.

25.2 Final Speed Certificate:

Final speed certificate of the machine shall be given after conducting detailed oscillation
trials of the machine. For this purpose, railway shall conduct running speed tests on the
Indian Railways main line track on one of the machines supplied to them preferably within
warranty, in accordance with procedure outlined in Annexure-II with the machine running up
to speed 10% higher than the maximum speed mentioned in clause 2.13 above.

26.0 MARKING & COLOUR OF MACHINE:

26.1 The machine body shall be painted in golden yellow colour of Indian Standard Colour Code
of 356 as per IS: 5 or RAL No. 1028 - Melon yellow. The exterior painting shall be
polyurethane binder based conforming to RDSO Specification No. M&C/PCN/100/2013
(Specification for Epoxy cum Polyurethane Painting System–two packs for the exterior
painting of railway coaches, diesel and electric locomotives and other industrial
applications) or ISO:12944.

26.2 Following shall be written in black on the machine at appropriate location in English & Hindi
as per direction of Indian Railways official:

i) India Railways logo of height between 300 mm to 600 mm as suitable on all four faces
of the machine.

ii) The text “INDIAN RAILWAYS” shall be written in bold and in black colour of size equal
to or slightly smaller than the size of logo but of size not less than 250 mm on both
side faces and below the Indian Railways logo.

iii) Machine model and manufacturing year shall be written in black colour and in letter of
size less than the size in which Indian Railways is written but not less than 200 mm in
any case below the text “INDIAN RAILWAYS” mentioned above.

Page 23 of 39
 1421
2631744/2024/O/o PED/INFRA-1/RDSO
iv) If required, the manufacturers name may be written in size not more than 150 mm and
shall not be at more than four locations. Also, the manufacturer‟s logo may be provided
at not more than two locations and shall be of size less than 200 mm.

v) Suitable signage to warn the operator and machine working staff against the 25 KV
OHE shall be stenciled on the machine at appropriate location.
vi) The speed of machine in case self-propelled and in train formation shall be marked on
machines.

*****************

Page 24 of 39
 1422
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-I

Page 25 of 39
 1423
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-II
Acceptance Criteria during Oscillation Trials

1. The speed potential of the machine offered by the supplier should be established based
upon oscillation trials conducted in India. The tests will be conducted at speed usually 10%
higher than the maximum speed potential indicated by the supplier for the machine under
consideration and the following criteria satisfy for the same. For conducting the tests, a
section of mainline track will be selected as per Third Report of the Standing Criteria
Committee, Revision-1: Criteria for assessment of stability/riding of rolling stock, (Document
No. TG-CR-4.2.3-2, March 2013) with latest amendment over which there are no temporary
speed restrictions and which is considered by the Railway as being in a generally run-down
condition for mainline standards, but without speed restrictions. The vehicle will be tested
generally for new and worn clearance conditions and where relevant for operation in the
forward and backward directions. The vehicle selected for tests will be one in average
condition for normal maintenance.

2. The criteria applicable for establishing speed potential as per Third Report of the Standing
Criteria Committee as applicable on date (21.04.2022) is given below for general information
purpose which may be amended from time to time:

i) A lateral force lasting over a length of more than 2 m should not exceed the
Prud-Homme‟s limit of k (1+P/3) tones. Where P is the axle load in tones, k=0.85
for wooden sleepers and k=1 for concrete sleepers.
ii) ii) Isolated peak values exceeding the above limit are permissible provided the
record shows establishing characteristics of the vehicle subsequent to the
disturbance.
iii) A derailment coefficient should be worked out in the form of ratio between the
lateral force (Hy) and the wheel load (Q) continuously over a period of 1/20th
second; the value HY/Q shall not exceed 1.
iv) The values of acceleration recorded in the cab at location as near as possible to
the bogie pivot (as near as possible to axle in case of four wheelers) shall be
limited to 0.55gboth in vertical and lateral directions. The peak values up-to 0.6 g
may be permitted if the records do not indicate a resonant tendency in the region
of peak value.
v) In the case of such vehicles where measurement of forces is not possible, the
evaluation shall be in terms of ride index based on the accelerations measured
as detailed in Para2 (iv) above which shall not be greater than 4.5 but a limit of
4.25 is preferred.
vi) A general indication of stable running characteristics of the vehicle as evidenced
by the movement of the bogie in straight and curved track with cant deficiency as
prescribed in IRPWM-June, 2020 with latest amendment and lateral force and
derailment coefficient of accelerations as the case may be.

3. SELECTION OF TEST TRACK (Third report of the standing criteria committee, revision-1:
Criteria for assessment of stability/riding of rolling stock, (Document No. TG-CR-4.2.3-
2March-2013) with latest amendment:

3.1. Oscillation trials shall be conducted over a section containing the following:

(i) A Tangent (straight) track - of about 1 km length. Efforts shall be made to conduct
trials over two such stretches.
(ii) A Station Yard having facing/trailing points, and
(iii) A curved track having about 2ºcurves of length about 700-800m. Normally, above
criteria shall be applicable. However, in case of non-availability of 2ºcurves fit for
requisite speed, following shall be applicable:
Page 26 of 39
 1424
2631744/2024/O/o PED/INFRA-1/RDSO

 For C&M I Vol I Standard Track: A curved track having 1.75º to 2.2ºcurve of about700-
800 m and a curved track having 0.5º to 1ºcurve of length about 700-800 m.

 For other than C&M I Vol I Standard Track: A curved track having 1.750to 2.20 curve of
about 700-800 m and a curve track having 10to 1.50curve of length about 700-800 m.

3.2. Indian Railways track is classified in two categories:

 Main line track - fit for operation less than 110 Kmph,
 High Speed (C&M I Volume I) track, permitting operation upto 160 kmph.

3.3. Since main line standard track permits speeds less than 110 kmph, in case the test
vehicle is designed to run at speeds 110 kmph and beyond, its Oscillation trials become
necessary on High-Speed track also.

3.4. A vehicle suspension should be so designed that it should be able to run freely on all
Indian Railways tracks (in certain cases, it may become necessary to place a restriction
in running of vehicle on some track structures due to various reasons). Since Oscillation
trials cannot be conducted all over the Railway system, the section chosen for detailed
Oscillation trials should be a representative „run down‟ section. The section should
generally be such that 90% of Indian Railways track should be better than this section -
the philosophy being that if a vehicle manages to run satisfactorily on this track stretch,
it will be able to run satisfactorily anywhere else on Indian Railways.

3.5. At present, the track geometry parameters are 'peak based' and not Standard Deviation
based. Subject to fulfilment of stipulations of 2.4 above, the parameters of the selected
track should be as per the following:

Parameters Main line Standard (Speeds below 110 kmph)

Unevenness B or C

Twist B or C or D

Gauge B or C

Alignment B or C

Parameters Category Extent of irregularities

Broad Gauge
(1) Unevenness (3.6 M chord). A 0-6 mm. (inclusive)
B 6 mm. (exclusive) to 10 mm. (inclusive)
C 10 mm. (exclusive) to 15 mm. (inclusive)
D Above 15 mm

(2) Twist (3.6 M base) A 0-5.0 mm. on chart (up-to and inclusive
of 1.39 mm./M)
B 5-7.5 mm. on chart (1.39 mm./M to 2.08
Note- 1 mm./M = 3.6 mm./M inclusive)
mm. on chart C 7.5-10.0 mm. on chart (2.08 mm./M to
2.78 mm./M inclusive)
D Above 10.00 mm. on chart (above 2.78
Page 27 of 39
 1425
2631744/2024/O/o PED/INFRA-1/RDSO
mm./M.)

(3) Gauge A Up-to and ±3 mm. (inclusive)

B ±3 mm to & ±6 mm. (inclusive)
C Above ±6 mm

(4) Alignment (7.2 M. A Up-to 3mm versine (inclusive)

chord) B More than 3 mm and less than 5 mm
versine.
C 5 mm. versine and above.

For certain trials only limited sections can be available due to constraints of axle load,
speeds, bridges, signaling, structures etc. For such limited sections, if test stretches are
not available as per above criteria, stretches should generally be selected such that
90% of the track of these limited sections should be better than the stretch chosen for
conduct of trials for issue of speed certificate. However, the limitation of trial shall be
clearly indicated in speed certificate issued subsequent to such trials.

3.6. After detailed oscillation trials have been completed and the safe speed thereby
determined, a „Long Confirmatory Run‟ should be conducted in each of the
configurations as per requirement. The basic idea of the „long run‟ is to confirm that the
values of parameters are in general conformity with the values found in the detailed trial
section.

(a) Cover a long distance (say, 10-50 kms) at the maximum speed determined by
oscillation trials of the configuration.
(b) Cover a few „hard spots‟ like level crossings, culverts and bridges as far as
possible. Riding of the vehicle over such points (resonance or amplitude build
up) will be specially mentioned in the trial report.

Page 28 of 39
 1426
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-III

INSPECTION CERTIFICATE

CERTIFICATE OF INSPECTION OF TRACK MACHINE (...............) BY INSPECTING OFFICIAL

AND APPROVAL FOR DISPATCH OF MACHINES.
(STRIKE OUT WHICHEVER NOT APPLICABLE)

This is to certify that I have inspected the machine

(type)_______________________________bearing Sl.No._________________ from (date)
____________to _____________at (Place) ________________ for its conformity/non-
conformity with respect to the laid down Technical Specifications in contract Agreement
No.__________________________ dated___________between President of India through
Director Track (Machines) and M/s. (Name of Supplier) ______________________________.

The detailed inspection note regarding its conformity/non-conformity to the laid specifications is
enclosed along with this certificate. It is observed that (strike out whichever is not applicable):-

 The machine conforms to all the laid down specifications.

 The machine conforms to all the laid down specifications except those at
Sl.No.________________________.
 The above deviations are minor/major affecting/not affecting the performance of the equipment in
substantial way.

The following T and P/manuals/drawings are to be supplied along with the machine:

1. __________________________
2. __________________________
3. __________________________

Based on the above, the machine is certified/not certified to be conforming to the specifications.

The machine is approved/not approved for dispatch to_____________(Consignee) Indian Railway.

SIGNATURE AND DATE

For M/s.__________________ INSPECTING OFFICIAL
_________________________ (NAME AND DESIGNATION)
for and on Behalf of President of India

Page 29 of 39
 1427
2631744/2024/O/o PED/INFRA-1/RDSO

Annexure-IV

Particulars Required in Respect of the Rolling Stock under Consideration

1. A diagram showing elevation with salient dimensions :

a) Wheel spacing, Wheel diameter, bogie centres, and axle load.

I. Overall length of the vehicle :

II. Length over head stock :
III. Length over buffers :
IV. Distance apart for center of buffers :
V. Max./Min. height of centers of buffers (above rail level) :

b) I. Wheel base :
II. Axle load (max) :
III. Maximum axle load per meter :
IV. Type of bogie :
V. Weight of each bogie :
VI. Weight of each bolster :
VII. Bogie Centres :

2. Wheel dimension :
I. New :
II. Worn out :

3. I. Tread and flange profile of the wheel indicating clearly :

whether it is Indian Railways standard profile or differs
from standard flange profile.
II. Wheel gauge dimension (back-to-back of tyre flange). :

4. Whether the stock is designed to be used as a general purpose or in a closed

circuit in specified sections under defined conditions. :
5. Maximum design speed :
I. Own Power :
II. In train formation

6. Unsprung weight per axle in tonnes

I. Driving axle :
II. Running axle :

7. Sprung weight per axle in tonnes

I. Driving axle :
II. Running axle :

8. Sprung mass on primary suspension :

9. Stiffness of suspension coil spring/magi spring :

10. Rate of deflection of primary spring :

Page 30 of 39
 1428
2631744/2024/O/o PED/INFRA-1/RDSO

11. Number of springs per nest :

12. Expected lateral force in tonnes per axle at maximum design speed. :

13. Increase in the impact load during motion (Dynamic Augment) :

14. Method of operation -

Whether single only or coupling together is possible. If coupling is possible, the
number which can be coupled and what is trailing load. :

15. Maximum tractive effort at start and at the speed of operation -

I. At working drive at start :
at operation speed :
II. At transfer drive at start :
at maximum speed :
16. Maximum braking force coming on to the rails per wheel
at working axle :
at transfer axle :

17. Drawing indicating suspension arrangement details of bogie and axle. :

18. Height of centre of gravity from rail level. :

19. Height of floor from rail level. :

20. Type of coupler provided -Indian Railways Standard

I. Coupling :
II. Buffer :

21. Engine Make, Model, Power Rating etc.

22. Any infringement to the moving dimensions :

(Sketch provided in the Indian Railways Standard Schedule of Dimensions –
Chapter IV (A)).

Page 31 of 39
 1429
2631744/2024/O/o PED/INFRA-1/RDSO

Annexure-V

Following information as detailed below is required for processing the case for issue of
provisional speed certificate for new machine

Name of the machine _____________________Model_______________________

S.No Item

1. a) Brake System details

b) Gross Braking Ratio
2. Brake rigging arrangement drawing and calculation of braking force
3. Maximum Braking Effort. at start and at the speed of operation -
a) at working drive at start :
at operation speed :
b) at transfer drive at start :
at maximum speed :
4. Characteristics of springs used in suspension indicating free height, solid height, working
height, dynamic range, stiffness and locations etc.
5. Characteristics of the dampers if used, and over all damping factors and locations of
dampers.
Calculation of the following frequency of the vehicle to be attached: -
i) Bouncing ii) Pitching iii) Rolling

Wave length of free axle and bogie

6. Write up and salient design calculation on suspension system, type of suspension-
whether it is of coil suspension with or without dampers and laminated bearing springs
and double link suspension.
7. What is lateral clearance of axle box / horn, wheel flange/rail and other locations for the
negotiability of the vehicle on curve and turn out (enclose Vogels Diagram for
negotiability on maximum degree of curve and turn out permitted on Indian Railways) of
new and worn-out wheel.
8. Wheel and axle assembly drawings
9. Calculation for flange force
10. Technical specifications of Vehicle supplied.
11. Calculation of natural frequency
12. Calculation of spring characteristics and critical speed of the vehicle.
13. Simulation result showing ride index, lateral force and acceleration results.
14. A certificate regarding the speed of the vehicle for which it has been designed.

Page 32 of 39
 1430
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-VI

Different Engineering materials of Indian Railways required to be loaded on the machine

Sr. Description Length Width Height Weight
No. (mm) (bottom) (mm) (Kg.) (approx.)
(mm)
1. Wider concrete sleeper 2750 285 235 350
2. Concrete Sleeper 2750 250 220 300
3. Wooden Sleeper 2750 250 130 100

4. Steel trough Sleeper 2680 257 106 79

5. 60 kg Rail (2 nos.) 6500 150 172 785
6. 60kg 1in 12 CMS crossing 4350 521 172 980
7. Abrasive rail Cutter 1070 420 950 30

8. Rail Drilling Machine 1030 450 570 60

9. Rail Tensor 1700 400 300 700

10. Alumino Thermit welding kit with two gas cylinders

Minor item 200
(one LPG/one Acetylene & Oxygen cylinder)
11. Weld trimmer 1200 620 280 150

12. Rail profile weld grinder 1020 460 350 80

13. 60 Kg Fish Plates, 2 pairs (4 pieces) 610 Minor 70

14. Torque wrench Minor items

15. Fish bolts Minor Items
16. Gang tools i.e Crow bars, hammers, rail tongs etc Minor Items
Note:1 A combination of the items listed above shall be required to be carried on the loading platform of
the machine as narrated in paragraph 2.15 of the specification and these items shall be in the working
reach of the crane described in paragraph 3.18 above.

2. Maximum load on the platform may be restricted up-to 7 t so, under frame and suspension may be
designed accordingly.
3. The loading platform shall be provided all-around with a sidewall/railing of about 450 mm to 600 mm
height to protect the men and materials from falling.
Details of rails and sleepers used for different Track structures

Sr. Rails Sleepers

No.
Rail Section Weigh Heigh Description Lengt Width Height Weig
t t (mm) h (bottom (mm) ht
(kg/m) (mm) ) (kg.)
(mm) (appr
ox.)
1. 60 kg 90 60.34 172 Wider concrete 2750 285 235 350
UTS Sleeper
2. 52 kg 90 51.89 156 Concrete Sleeper 2750 250 220 300
UTS
3. 52 kg 72 51.89 156 Wooden Sleeper 2750 250 130 100
UTS
4. 90 R 44.61 142.88 Steel Trough 2680 257 106 79
Sleeper

Page 33 of 39
 1431
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-VII

Page 34 of 39
 1432
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-VIII

Specifications of Heavy-duty Industrial Quality Water proof & shock proof

Laptop (Tough book)

CPU Intel Core i-5-7440HQ processor, speed 2.8 GHz up to 3.8

GHz Intel Core 13th Gen i-7 processor, speed 4.8 GHz or
higher version

Operating System Latest windows 10 11 professional or higher version

RAM 8 GB DDR4 32 GB DDR5 or more and expandable up to

64 128 GB

Storage Shock protected removable HDD SATA 500 GB SSD 1 TB

expandable up to 1 TB 2 TB

Display Minimum 15.6” 14” high-definition LED/TFT/LCD Full HD

with refresh rate of 144 Hz or better with sunlight readable
display, anti-reflective and anti-glare treatment.
Keyboard LED backlit 61 key QWERTY keyboard with integrated
numeric pad. Touchpad with vertical scrolling support.
Wireless Integrated Gobi 2000 Mobile broadband 4G/5G LTE and
GPS support or better, minimum Bluetooth V 4.0 5.0 or
better.
Durability features Product shall be fully rugged, durable and meet the latest
MIL standard.
Moisture/water and dust resistant screen (IP66), Key board
and touch pad.
Pre-Loaded Software‟s Latest Antivirus software for 18 months validity Microsoft
office 2007 standard 2021 or latest complete bundle
(Licensed copy with CD backup)
Power supply Long life Li-ion battery, minimum 8700 m AH with 18 hours
operating battery backup.

Warranty 5-year warranty

Page 35 of 39
 1433
2631744/2024/O/o PED/INFRA-1/RDSO

Annexure-IX

BRAKE DESIGN DETAILS OF THE MACHINE FOR

CALCULATION OF EMERGENCY BRAKING DISTANCE

1. Tare & gross weight of the vehicle in Kilograms

2. Brake power in Kilograms
3. Type of Brake blocks
4. Brake block area in Square Centimeters
5. Brake Rigging Diagram
6. Type of Brake system

Page 36 of 39
 1434
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-X

Machine data to be submitted along with dynamic simulation report of the machine

Parameters required
C.G. of component in Mass in kg and mass moment of inertias in kg.
x, y, z direction from m2 of component in three-dimension space
S.No. Component‟s rail level in mm about their C.G.
Name (reference point 1st
axle)
X Y Z Mass Ixx Iyy Izz
1. Super structure
with vehicle
frame (Vehicle
structure kept
on secondary
suspension of
front and rear
bogie)
2. Front Bogie
frame including
brake rigging
3. Rear Bogie
frame including
brake rigging
4. Transmission
system device
(hydraulic.
Mechanical or
electrical
traction motors
5. Wheel axle set
including axle
boxes which
constitute the
unsprung mass
6. Mass of Items 1 2 3 4 5 6 Total
included in unsprung
unsprung mass mass in
partially or fully tonnes
along with their
name per axle
7. Total weight of Front bogie Rear bogie full vehicle Full weight of vehicle
components in full assembly assembly frame (Front bogie + rear
tonnes full bogie +vehicle car
structu body or super
re structure)

8. Suspension Primary suspension element stiffness Secondary suspension element

stiffness details per axle box between bogie and axle stiffness per side between
in kg/mm box bogie and vehicle frame
Vertical Lateral Longitudinal Vertica Lateral Longitudinal
stiff stiff stiff l stiff stiff stiff

Page 37 of 39
 1435
2631744/2024/O/o PED/INFRA-1/RDSO

9. Damping force
details
(If hydraulic
damper used
give there rating
force per
meter/second)
10. Clearance in Vertical Lateral Longitudinal Rotatio Rotation Rotation
mm or radian direction direction direction n about about
provided for about Lateral Longitudinal
motion between vertical axis axis
bogie frame and axis
vehicle frame
for relative
motion (motion
stopper)
11. Dimension of Detail of location of suspension Detail of location of suspension
location of springs and dampers and shock springs and dampers and shock
suspension absorbers with support drawing absorbers with support drawing
elements
12. Details of centre Provide detail arrangement drawing and description
pivot
arrangement
working and
location
13. Set of drawings Concerning with general arrangement of vehicle, bogie general
and design arrangement, suspension arrangement details, suspension clearances
description drawing, detail written description of configuration and loading pattern
accompanies design particular of vehicle bogie.

Page 38 of 39
 1436
2631744/2024/O/o PED/INFRA-1/RDSO
Annexure-XI

Salient features of the Braking System of the Machine

1.0 Braking System

Machine should be equipped with proper braking system to ensure safety and controls
the machine in case of an emergency as well as in routine operation while moving in
travel, working and train formation mode.
1.1. The machine shall be fitted with the compressed air brakes system which shall apply
brake equally on all wheels and provision shall be made to connect the Indian Railways
standard locomotives.
2.0 Vehicle should have provision of following braking mechanism.
2.1. Direct Brakes:
Machine should have provision of direct braking system to be operated by compressed
air. The pneumatic valve should be provided to operate at system pressure of 7 kgf/cm 2
with dual type pressure gauge, Air regulator and Reservoir. SA-9 Brake system with
hand lever being used in Indian Railways may also be used. Effective braking distance
certificate should be submitted at ruling gradient of 1 in 33, 1 in 60 and for flat locations.
This system is applicable for machine braking only. This system should be provided in
both cabins.
2.2. Indirect Brake:
Indirect Brake should be capable to stop the machine in case of pressure drop and
should be compatible to connect with Indian Railways standard locomotives. This
indirect braking system should have separate Air reservoir, KE valve and Air charging
valve with through connected steel Brake pipes to connect Locomotives in travel mode
during pulling of vehicle in train formation. System may have existing braking A-9 type of
valve being used in Indian Railways. Manufacture design should have compatibility to
connect Locomotive of Indian Railways train brake system. This system should be
provided in both cabins.
2.3. Emergency Brakes:
This system should be connected with indirect braking system for sudden braking in
emergency. This system shall be equipped with Pneumatic valve. Operation of
Pneumatic valve should be with hand lever. This emergency system shall be connected
with BP of machine and shall be operative through indirect braking system. This system
should be provided in both cabins.
2.4. Mechanical Parking brake:
Machine should be equipped with wheel operated system connected to braking lever
with rigid chain link arrangement. This system should be capable to stop the machine in
rolling condition during emergency. This shall also be used after parking of machine to
prevent rolling of machine in standstill condition. This system should be provided in one
cabin only.
2.5. Parking brake:
Machine should be equipped with spring loaded pneumatically operated parking brake
system. In this system, braking of one bogie is to be carried out with spring loaded
Pneumatic Cylinder. Brake should automatically be applied on wheels if air pressure falls
below 3 bar or by application of knob after parking of vehicle. There shall be also an
easy arrangement to release the parking brake in case of emergency.
Page 39 of 39